Land Rover Defender: Intake Manifold - Ingenium I4 2.0l Petrol

REMOVAL AND INSTALLATION

PART(S)

REMOVAL

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Raise and support the vehicle on a suitable 2 post lift.

2. Disconnect the startup battery ground cable.

3. Partially drain the cooling system.

4. Remove the engine cover.

5. Remove the secondary bulkhead center panel.

6.

WARNING: Be prepared to collect escaping fuel.

• Release the 2 clips.
• Release the 2 fuel line clips.
• Disconnect the 2 fuel lines.

7.

• Release the 3 fasteners.
• Remove the Noise, Vibration and Harshness (NVH) material.

8.

• Disconnect the breather pipe from the engine vent oil separator.
• Disconnect the breather pipe from the intake manifold.
• Remove the breather pipe.

9.

CAUTION: Be prepared to collect escaping coolant.

• Release the coolant hose clip.
• Disconnect the coolant hose.
• Reposition the coolant hose away from the intake manifold.

10.

• Remove the 2 bolts.
• Release the clamp.
• Disconnect the coolant pipe from the coolant hose.
• Remove the coolant pipe.

11.

• Release the coolant hose clip.
• Disconnect the coolant hose from the thermostat housing.
• Remove the coolant hose.

12.

• Disconnect the fuel vapor pipe from the charge air cooler outlet pipe.
• Release the 2 clips.
• Disconnect the fuel vapor pipe from the intake manifold.
• Disconnect the fuel vapor pipe from the purge valve.
• Release the clip.
• Disconnect the electrical connector from the purge valve.
• Release the purge valve from the clip.
• Remove the purge valve assembly.

13.

• Release the clip.
• Reposition the vacuum pipe away from the intake manifold.

14.

CAUTION: Be prepared to collect escaping coolant.

• Remove the 3 bolts.
• Release the 3 clamps.
• Disconnect the 3 coolant hoses from the coolant pipe.
• Remove the coolant pipe.

15.

• Disconnect the electrical connector from the Manifold Absolute Pressure and Temperature sensor (MAPT) sensor.
• Disconnect the electrical connector from the knock sensor.
• Release the clip.
• Release the wiring harness from the clip.

16.

• Disconnect the electrical connector from the throttle body.
• Release the clip.

17.

• Release the clamp.
• Disconnect the charge air cooler outlet pipe from the throttle body.

18.

Remove the bolt.

19.

CAUTION: Be prepared to collect escaping coolant.

• Release the clamp.
• Disconnect the coolant hose from the thermostat housing.

20.

NOTE: The 6 intake manifold bolts are captive.

• Loosen the 6 bolts.
• Remove the highlighted bolt.
• Remove the intake manifold.

21.

NOTE: Do not disassemble further if the component is removed for access only.

Remove and discard the 4 seals.

22.

NOTE: This step is not required if the component is removed for access only.

• Remove the bolt.
• Remove the MAPT sensor.

23.

NOTE: This step is not required if the component is removed for access only.

• Remove the 4 bolts.
• Remove the throttle body.
• Remove and discard the gasket.

INSTALLATION

1.

NOTE: This step is not required if the component is removed for access only.

• Install a new throttle body gasket.

  Renew Part: Throttle body gasket Quantity: 1.

• Install the throttle body.
• Install and tighten the 4 bolts in the illustrated sequence.

  Torque: 12Nm

2.

NOTE: This step is not required if the component is removed for access only.

• Install the MAPT sensor.
• Install and tighten the bolt.

  Torque: 5Nm

3.

Install 4 new intake manifold seals.

Renew Part: Intake manifold seals Quantity: 4.

4.

• Install the intake manifold.
• Install, but do not fully tighten the highlighted bolt.
• Tighten the 7 bolts.

  Torque: 12Nm

5.

• Connect the coolant hose to the thermostat housing.
• Install the clamp.

6.

• Reposition the oil level gauge in the correct location.
• Install and tighten the bolt.

  Torque: 8Nm

7. Connect the charge air cooler outlet pipe to the throttle body.

8.

• Connect the electrical connector to the throttle body.
• Install the clip.

9.

• Connect the electrical connector to the MAPT sensor.
• Connect the electrical connector to the knock sensor.
• Install the 2 clips.

10.

• Install the coolant pipe.
• Install and tighten the 3 bolts.

  Torque: 10Nm

• Connect the 3 coolant hoses to the coolant pipe.
• Install the 3 clamps.

11.

• Reposition the vacuum pipe into the correct location.
• Install the clip.

12.

• Install the purge valve assembly.
• Connect the fuel vapor pipe to the intake manifold.
• Connect the fuel vapor pipe to the charge air cooler outlet pipe.
• Connect the fuel vapor pipe to the purge valve.
• Install the 2 clips.
• Connect the electrical connector to the purge valve.

13.

• Install the coolant hose.
• Connect the coolant hose to the thermostat housing.

14.

• Install the coolant pipe.
• Install and tighten the 2 bolts.

  Torque: 10Nm

• Connect the coolant hose to the coolant pipe.
• Install the clamp.

15.

• Connect the coolant hose to the coolant pipe.
• Install the coolant pipe clip.

16.

• Install the breather pipe.
• Connect the breather pipe to the intake manifold.
• Connect the breather pipe to the engine vent oil separator.

17.

• Install the NVH material.
• Install the 3 fasteners.

18. Connect the 2 fuel lines.

19. Install the secondary bulkhead center panel.

20. Install the engine cover.

21. Vacuum fill the cooling system.

22. Connect the startup battery ground cable.

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